US20080115906A1 - Method and Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster - Google Patents
Method and Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster Download PDFInfo
- Publication number
- US20080115906A1 US20080115906A1 US11/562,598 US56259806A US2008115906A1 US 20080115906 A1 US20080115906 A1 US 20080115906A1 US 56259806 A US56259806 A US 56259806A US 2008115906 A1 US2008115906 A1 US 2008115906A1
- Authority
- US
- United States
- Prior art keywords
- chamber
- belt
- steel
- liquid
- metallic bath
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 23
- 238000005058 metal casting Methods 0.000 title description 2
- 239000007788 liquid Substances 0.000 claims abstract description 59
- 238000001816 cooling Methods 0.000 claims abstract description 40
- 238000005266 casting Methods 0.000 claims abstract description 35
- 239000012535 impurity Substances 0.000 claims abstract description 33
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 20
- 229910052751 metal Inorganic materials 0.000 claims abstract description 18
- 239000002184 metal Substances 0.000 claims abstract description 18
- 239000007787 solid Substances 0.000 claims abstract description 13
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 28
- 239000007789 gas Substances 0.000 claims description 24
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 23
- 239000000395 magnesium oxide Substances 0.000 claims description 23
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 23
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- 229910052799 carbon Inorganic materials 0.000 claims description 16
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims description 10
- 239000002893 slag Substances 0.000 claims description 9
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 7
- 229910002092 carbon dioxide Inorganic materials 0.000 claims description 5
- 239000001569 carbon dioxide Substances 0.000 claims description 5
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 5
- 239000011800 void material Substances 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- DLYUQMMRRRQYAE-UHFFFAOYSA-N tetraphosphorus decaoxide Chemical compound O1P(O2)(=O)OP3(=O)OP1(=O)OP2(=O)O3 DLYUQMMRRRQYAE-UHFFFAOYSA-N 0.000 claims description 3
- 239000011261 inert gas Substances 0.000 claims description 2
- 230000004927 fusion Effects 0.000 claims 1
- 238000007790 scraping Methods 0.000 claims 1
- 229910000831 Steel Inorganic materials 0.000 abstract description 115
- 239000010959 steel Substances 0.000 abstract description 115
- 238000007711 solidification Methods 0.000 abstract description 17
- 230000008023 solidification Effects 0.000 abstract description 17
- 229910001338 liquidmetal Inorganic materials 0.000 abstract description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 abstract description 5
- 239000001301 oxygen Substances 0.000 abstract description 4
- 229910052760 oxygen Inorganic materials 0.000 abstract description 4
- 229910000975 Carbon steel Inorganic materials 0.000 abstract 1
- 229910000742 Microalloyed steel Inorganic materials 0.000 abstract 1
- 238000005204 segregation Methods 0.000 description 32
- 210000001787 dendrite Anatomy 0.000 description 14
- 235000013980 iron oxide Nutrition 0.000 description 13
- 230000008569 process Effects 0.000 description 12
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 11
- 238000007789 sealing Methods 0.000 description 11
- 238000009749 continuous casting Methods 0.000 description 9
- 239000008187 granular material Substances 0.000 description 9
- 239000000243 solution Substances 0.000 description 9
- 230000015572 biosynthetic process Effects 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 229960004424 carbon dioxide Drugs 0.000 description 6
- 239000000498 cooling water Substances 0.000 description 6
- 229910002090 carbon oxide Inorganic materials 0.000 description 5
- 230000001965 increasing effect Effects 0.000 description 5
- 238000005755 formation reaction Methods 0.000 description 4
- 239000002667 nucleating agent Substances 0.000 description 4
- 230000009467 reduction Effects 0.000 description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 238000005275 alloying Methods 0.000 description 3
- 239000012267 brine Substances 0.000 description 3
- 238000005262 decarbonization Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 3
- 238000003786 synthesis reaction Methods 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- YWEUIGNSBFLMFL-UHFFFAOYSA-N diphosphonate Chemical compound O=P(=O)OP(=O)=O YWEUIGNSBFLMFL-UHFFFAOYSA-N 0.000 description 2
- 230000005012 migration Effects 0.000 description 2
- 238000013508 migration Methods 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 229910052698 phosphorus Inorganic materials 0.000 description 2
- 239000011574 phosphorus Substances 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 206010039509 Scab Diseases 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 210000004027 cell Anatomy 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000004503 fine granule Substances 0.000 description 1
- 230000008014 freezing Effects 0.000 description 1
- 238000007710 freezing Methods 0.000 description 1
- 230000001939 inductive effect Effects 0.000 description 1
- VBMVTYDPPZVILR-UHFFFAOYSA-N iron(2+);oxygen(2-) Chemical class [O-2].[Fe+2] VBMVTYDPPZVILR-UHFFFAOYSA-N 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- PWPJGUXAGUPAHP-UHFFFAOYSA-N lufenuron Chemical compound C1=C(Cl)C(OC(F)(F)C(C(F)(F)F)F)=CC(Cl)=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F PWPJGUXAGUPAHP-UHFFFAOYSA-N 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 210000002445 nipple Anatomy 0.000 description 1
- 238000010606 normalization Methods 0.000 description 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 238000010587 phase diagram Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000011946 reduction process Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000007790 solid phase Substances 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/001—Continuous casting of metals, i.e. casting in indefinite lengths of specific alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0631—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by a travelling straight surface, e.g. through-like moulds, a belt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0637—Accessories therefor
- B22D11/068—Accessories therefor for cooling the cast product during its passage through the mould surfaces
- B22D11/0685—Accessories therefor for cooling the cast product during its passage through the mould surfaces by cooling the casting belts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
- B22D11/0637—Accessories therefor
- B22D11/0697—Accessories therefor for casting in a protected atmosphere
Definitions
- the present invention relates generally to Casting of steel. More particularly, the present invention relates to metal casting where the steel is horizontally cast and cooled on one side from the bottom minimizing the inclusions of formation of impurities in the steel by increasing negative segregation and also producing steel that has fine grained equal axial structure.
- cast steels have been produced by casting molten steel (consisting mainly of reduced iron oxide) into slabs, blooms, billets and cast strips, etc. through ingot casting methods using fixed molds and through continuous casting methods using slip molds, belt casters and strip caster, etc. and by cutting them into prescribed sizes.
- Continuous casting of steel has been achieved by pouring liquid steel in a vertical mold and extracting the steel from the bottom of the mold after solidification is completed.
- Continuous casting of steel has great advantages over fixed volume mold castings.
- the rate of liquid steel flow into the mold, the cooling rate of the steel, and the migration and segregation is near constant resulting in near 100% yield.
- the surface texture of the steel is excellent.
- One disadvantage of vertical continuous steel casting is the positive segregation that occurs in the interior of the casting. This positive segregation generally results in inclusions and lower steel quality.
- Many patents have improved the quality of steel produced from continuous casting—for example U.S. Pat. Nos. 6,585,799 (2003) and 6,918,969 (2005) both to Zeeze et a.—but none similar to the Sealed Table Caster.
- the crystalline granule structure is determined by (1) keeping the difference in the temperature between liquid steel and the solidified steel to a minimum, (2) inducing flow or movement of the liquid steel across the solidifying dendrite, thus maintaining a consistent solution chemically and physically (3) insuring the high frequency of nuclei in the molten steel, and (4) allowing negative segregation to continue through the final solidification of the steel and eliminating inclusions. These factors are important in the formation of a high quality steel.
- Negative segregation is the process of the impurities migrating transversely, perpendicular from the heat sink, and as the solidification in the liquid portion of the steel continues.
- Positive segregation is the accumulation of impurities in the confined liquid portion of the steel. Impurities collect in the liquid portion of the steel. This process is similar to the formation of sea ice and brine pockets. When sea ice dentrites form, the salt in the water is rejected in a process called brine rejection. As a result no salt is formed in the dentrites but is pushed into pockets or highly concentrated brine.
- the impurities in the liquid steel may to a degree, migrates to the upper region of the ingot as solidification takes place at the bottom.
- the supper region of the ingot has accumulated a great portion of the impurities through segregation and circulation and buoyancy of the impurities. Consequently the lower section of the ingot usually has the higher quality of steel. Because the upper section has a high concentration of impurities the excess of the provision is usually cropped off and rejected during the slab rolling procedure.
- the main objective of the present invention is to provide a continuous casting method and apparatus that promotes negative segregation without the consequence of positive segregation of the interior as the steel solidifies resulting in higher quality steel with minimal inclusions.
- Producing an equal axial fine grained crystalline structure being consistent chemically and physically, having excellent qualities such as: tensile strength, modulus of elasticity, toughness, ductility, workability, etc.
- the process described below has the object to reduce the cost for a superior nucleation agent, reduce the cost of decarbonization and deoxidization materials for producing a high quality steel void of oxidation point defects.
- the process also provides flexibility in casting dimensions, both width and thickness, thus reducing the operational and tool cost for producing a wider range of products and lowering the energy required for rolling reduction of the steel.
- the invention is directed to a sealed table caster.
- the sealed table caster has a chamber with an opening, to allow a liquid to flow into the chamber.
- a cooling belt running along the bottom of the chamber causes the liquid to solidify while maintaining a layer of liquid on top of the solidified portion of the liquid.
- the belt moves the solidified steel toward the exit of the chamber and the liquid is poured into the chamber such that is causes the liquid steel to circulate on the solidified steel.
- a cooled roller with the sealing roll both equipped with a scraper that may be places on top of the liquid to remove rejected impurities floating on the top layer of the liquid steel.
- FIG. 1 is a perspective view of a table caster in accordance with an embodiment of the present invention
- FIG. 2 is a cross-sectional view of the table caster
- FIG. 3 is a perspective view and traverse section of the beginning section of the table caster
- FIG. 4 is a perspective view of cooling fountains
- FIG. 5 is a side view of a cooling fountain.
- FIG. 6 is a high temperature reactor.
- FIG. 7 is a phase diagram of the solubility of magnesium oxide with iron oxide.
- the horizontal table caster 10 has a receiving tube 12 connected to a tundish (not shown). Typical materials used in casting can be used in constructing the horizontal table caster and such materials are well known in the art.
- the top of the table caster 10 has removable hood 14 .
- the hood 14 creates a sealed chamber 16 around cooling belt 18 .
- Chamber 16 can be any shape as long as it provides a seal around belt 18 . It is preferable for belt 18 to be made of copper but any suitable material can be used.
- Gas inlet 20 allows a gas to enter chamber 16 , creating a protective and cooling gaseous atmosphere and gas outlet 22 allows the gas to exit the chamber 16 .
- the protective gas maintains an ideal gas coverage over the molten metal, gas free of harmful vapor.
- the gas can be a reducing or an inert gas such as carbon monoxide, carbon dioxide or argon.
- Hood 14 is cooled by water duct 24 .
- Duct 24 receives and discharges water from a pressurized water sources (not shown).
- the exit 26 (for the cast metal) of chamber 16 is sealed by two inch sealing rolls 28 .
- the rolls 28 keep gas from escaping chamber 16 while allowing the solidified steel to exit and assist in the constant movement of the solid steel.
- Chamber 16 is scaled on the opposite end by sealing rolls 29 ,
- Belt 18 is driven by drive drum 30 and rotates around idler drum 32 .
- Belt scrapers 34 touches sealing rolls 29 and belt 18 .
- Drains 36 allow cooling water to exit the table and are provided with a gas seal (not shown).
- Pouring table 38 supports the cooling fountain which in turn supports the cooling belt and steel.
- Normalizing table 40 supports the steel during and after heat extraction has occurred and solidification and normalization is becoming completed.
- FIG. 2 shows a cross section of the sealed casting table 10 .
- Circular deflector 42 is supported and rotated by an apparatus (not shown) and located down stream from tube 12 .
- Deflector 42 is made of a ceramic but it can be made of any suitable material.
- Optional cooling roller 44 rotates in a direction opposite the direction of belt 18 .
- Roller 44 is cooled by a pressurized water source (not shown) and cleaned by drum scraper 46 .
- Cooling fountains 47 and belt 18 are supported by structural water boxes 48 .
- Adjustable cooling walls 49 are located on either side and above belt 18 . Walls 49 are adjusted with envelope holding arms 49 A.
- Water boxes 57 are connected to a pressurized water source (not shown).
- Normalizing table 40 consist of rollers 50 and base rollers 52 .
- Base rollers 52 are connected to bottom of table 40 .
- the table caster 10 is supported by jack pedestal 55 , jack 55 A, and supports 55 B and 55 C.
- Table caster is adjusted with tension jack 55 D.
- Blow up 81 shows a magnified view of table caster 10 .
- Liquid steel 82 consists of two parts, upper portion 89 and lower portion 90 .
- the liquid steel is located above the solidified steel 92 .
- Flow arrows 94 show how upper and lower portions 89 and 90 moves in relation to the solidified steel 92 .
- FIG. 3 illustrates a perspective cut section of one end of the horizontal table caster.
- Walls 49 are adjusted with arms 49 A.
- the bottom of cooled side walls 49 has gas sealing canal 56 .
- Pressurized gas fills gas sealing canal 56 to prevent leakage of molten metal under the cooled side wall 49 at a temperature well below boiling point.
- the hood 14 is supported on canal 58 .
- Canal 58 is filled with runoff water to create a gas seal for chamber 16 . Used cooling water flows into sluice trough 60 and out drain 36 . Cooling water also flows over hood 14 and is supplied by conduit 24 . Cooling water flows over hood 14 through conduit 24 .
- FIG. 4 shows a perspective view of cooling fountains 47 .
- Belt 18 (not shown) is supported by hydraulic pressure and floats on incoming water that flows though control orifice 64 and over rim 62 . Water flows to the underside of cooling belt 18 (not shown) through flow control orifice 64 .
- Bolts 66 provide support and anchor the cooling fountain 47 to water boxes 48 (not shown).
- Spacer 68 aligns adjacent cooling fountains together.
- FIG. 5 shows a side view of a cooling fountain 47 .
- Alignment nipple 70 is used to set the cooling fountain in structural water boxes 48 (not shown).
- Sealing ring 72 provides a water tight seal between the cooling fountain and the structural water boxes.
- FIG. 6 is the high temperature reactor 74 described in patent application Ser. No. 11/070527 filled Mar. 1, 2005, by Oren V. Peterson, entitled “Thermal Synthesis Production of Steel” FIG. 1 .
- the liquid metal 76 flows out port 78 into a ladle (not shown).
- Tap hole 80 can be used to drain the slag bath 84 on top of the liquid metal bath. Operation . . . FIG. 2 , FIG. 6 , FIG. 7 , and FIG. 8
- Liquid steel is prepared by the process as described in patent application Ser. No. 11/070527 filled Mar. 1, 2005, by Oren V. Peterson, entitled “Thermal Synthesis Production of Steel” and as further processed as herein described.
- the phosphorus in the heat of the steel is oxidized to phosphorus pentoxide with the iron oxide in the metallic bath and rises up into the slag bath as the on going partial reduction process proceeds.
- Carbon is added on top of the slag bath near the final stage of iron partial reduction of the heat of steel to remove the phosphorus pentoxide, by reduction and evaporation, from the slag bath, the slag 84 is drained off through tap hole 80 after the phosphorus removal is completed.
- Iron oxide and powdered magnesium oxide are then added to the bath. The iron oxide and magnesium oxide go into solution in the partially reduced metallic bath at temperatures above 2300 degrees Fahrenheit (See FIG. 7 ). Magnesium oxide has a simple cubicle crystalline structure.
- the magnesium oxide melting temperature is 5070 degrees Fahrenheit and iron oxide is 2300 degrees Fahrenheit, both are ionic bonds with the same valence so the iron oxide can substitute the magnesium oxide ion in the crystal structure allowing the magnesium oxide to go into solution both as liquid and suspended solid particles.
- the degree of solubility of magnesium oxide an iron oxide increase as temperature increases, thus the metallic bath temperature is now elevated. Once the degree of magnesium oxide is in solution with the iron oxide in the metallic bath, alloying materials and excess amounts of carbon are added into the solution and the carbon reacts with iron oxides in the solution. Excess amounts of carbon are added to reduce all metal oxides except the magnesium oxide, which is very chemically stable. Because the carbon deoxidation reaction is endothermic, carbon becomes an excellent deoxidation agent as metallic temperatures are increase.
- the carbon oxides escape from the metallic bath leaving the iron, carbon and magnesium oxide and alloying materials in the solution. Because of the mass action of the excess carbon and carbon monoxide this process leaves the molten metallic bath near void of oxygen, other than the magnesium oxide nuclei which is chemically stable and serves as a solid nucleation agent.
- the excess carbon can be removed by decarbonization.
- Decarbonization is the process of removing excess carbon by injecting carbon dioxide into the high temperature metallic bath. The carbon dioxide reacts with the carbon, at elevated temperatures, forming carbon monoxide and lowering the temperature of the metallic bath to casting temperature. This reaction removes the excess carbon from the metallic bath without oxidizing the iron.
- the magnesium oxide remains in the bath as nano-dimensional suspended solid particles that may serve as nuclei during solidification.
- the metallic bath flows out of the reactor and then is poured into a tundish.
- the liquid exits the tundish and enters chamber 16 through tube 12 .
- Circular deflector 42 deflects the vertical flow of the liquid steel 82 into a fanned horizontal flow directed in the opposite direction of travel of belt 18 .
- the addition of molten steel being poured onto the surface of the pool of liquid steel causes the upper strata of liquid steel to flow towards the sealing roll 29 , which is water cooled from the interior of the roll.
- the movement of cooling belt 18 and the flowing of the liquid steel into chamber 16 causes liquid portion of the steel to counter flow in strata on top of the solidified portion of the steel.
- the lower liquid portion of the steel 90 moves faster, toward the sealing rolls 28 than the solid portion of the steel 92 .
- This movement causes developing dendrite to break off at a the ends, minimizing columnar structural granules in the steel and creating dendrite nuclei.
- the rate of flow of the liquid steel 82 into chamber 16 , the temperature of cooling belt 18 , and the linear rate of the travel of the cooling belt 18 is coordinated such that a constant level of liquid steel is maintained in chamber 16 .
- the depth of liquid steel can be varied to produce different slab thicknesses.
- the induced flow mixes the liquid steel on the cooling belt 18 with the poured hot steel 82 , normalizing its temperature and insuring a uniformed solution, temperature, and solidification rate throughout the entire length of the casting and solidifying surface.
- fine granules of steel are forming, rejecting the impurities into the liquid steel.
- the fine granules form around the solid nano-dimensional magnesium oxide particles in the metallic bath solution.
- the liquid steel flows over the growing dendrite and breaks off the dendrite ends. This minimizes columnar growth, producing fragmented dendrite as nuclei, and carries the rejected impurities columnar growth, producing fragmented dendrite as nuclei, and carries the rejected impurities to the surface of the liquid steel. This rejection produces negative segregation resulting in minimal inclusions with a high purity of steel.
- roller 44 As the top layer of liquid (having the highest concentration of impurities) touches roller 44 it solidifies and sticks to the roller.
- Scraper 46 then removes the solidified slag or impurities from the roller 44 and is dispensed. It is recognized that the roller 44 and scraper 46 are optional.
- the upper surface of the casting, containing the impurities, may be scarified or ground to remove impurities.
- Cooling belt 18 is supported by multiple cooling water fountains 47 .
- the cooling water fountains maintain the cooling belt in an effective cooling range of temperatures by flowing water (or any other suitable cooling agent) on the underside of the cooling belt 18 .
- the discharged water flowing from the cooling fountains 47 is collected in sluice trough 60 and discharged through drains 36 .
- the liquid steel pool is contained by adjustable water cooled side walls 49 . Adjusting the side walls allows different cast widths to be formed with the same casting table.
- the liquid steel is contained by seal rolls 29 .
- the roll cleaning scraper 34 is used to keep the belt on idler drum 32 and sealing roll 29 free of metal debris or scabs.
- Expansion joint 54 are located above the drive drum 30 to allow for differential movement in the table caster 10 . Expansion joint 54 allows for difference in linear expansion of hood 14 and base 38 . Sealing pinch rolls 28 allow the solidified steel to exit, to assist in the constant movement of the casting, and to keep gas from escaping.
- the horizontal table caster allows for thinner and narrow castings of steel may maximizing the tonnage by producing longer castings.
- magnesium oxide as a nucleation agent creates a finer grain steel with superior mechanical characteristics than steel using aluminum oxide as the nuclei. Natural occurring magnesium oxide produces much smaller nuclei than other nucleation agents such as aluminum oxide It is also less expensive than metallic magnesium and aluminum. The magnesium oxide is a smaller nucleus than the aluminum and the columbic forces the reduced repulsion in its molecule enhances more rapid dendrite forming characteristics, resulting in finer equal axial grain steel.
- Carbon dioxide can be injected into the molten steel to oxidize excessive carbon, leaving near zero oxygen residue in the metallic bath, also being capable of lowering carbon to very low quantity for micro alloying. Adding oxygen to the metallic bath to remove the carbon will oxidize portion of the iron and requires large quantities of expensive deoxidizers to only partially reduce the residue of oxygen in the steel.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
Abstract
A method and apparatus for preparing and delivering various types of carbon and microalloy steel, free of oxygen with abundance of nuclei, when cast producing ultra fine grain steel free of internal defeats with excellent quality. A horizontal sealed table caster has a chamber, containing a suitable atmosphere for casting, with a tube connecting to a tundish so as to allow a liquid to flow into the chamber. The liquid metal is captured on a cooling belt along the bottom of the chamber and is maintained as a specific width and depth. The cooling belt serves as a heat sink causing the liquid metal to solidify from the bottom up, allowing inclusions to migrate to the surface of the steel. A layer of liquid metal is maintained on top of the solidifying steel until the solidification reaches the surface. The belt moves the solid metal toward the exit of the chamber. As the liquid metal solidifies the impurities migrate in the liquid metal, reaching the surface and a solid metal body free of inclusions with the superior properties is produced.
Description
- This application uses the liquid steel produced as disclosed in patent application Ser. No. 11/070527 filed Mar. 1, 2005, by Oren V. Peterson, entitled “Thermal Synthesis Production of Steel” which application is hereby incorporated by reference herein in its entirety with the following exception: In the event that any portion of the above-referenced application is inconsistent with this application, this application supercedes said above-referenced application.
- Not Applicable.
- Not Applicable.
- 1. Field of Invention
- The present invention relates generally to Casting of steel. More particularly, the present invention relates to metal casting where the steel is horizontally cast and cooled on one side from the bottom minimizing the inclusions of formation of impurities in the steel by increasing negative segregation and also producing steel that has fine grained equal axial structure.
- 2. Prior Art
- Until now, cast steels have been produced by casting molten steel (consisting mainly of reduced iron oxide) into slabs, blooms, billets and cast strips, etc. through ingot casting methods using fixed molds and through continuous casting methods using slip molds, belt casters and strip caster, etc. and by cutting them into prescribed sizes.
- Continuous casting of steel has been achieved by pouring liquid steel in a vertical mold and extracting the steel from the bottom of the mold after solidification is completed. Continuous casting of steel has great advantages over fixed volume mold castings. The rate of liquid steel flow into the mold, the cooling rate of the steel, and the migration and segregation is near constant resulting in near 100% yield. Furthermore, the surface texture of the steel is excellent. One disadvantage of vertical continuous steel casting is the positive segregation that occurs in the interior of the casting. This positive segregation generally results in inclusions and lower steel quality. Many patents have improved the quality of steel produced from continuous casting—for example U.S. Pat. Nos. 6,585,799 (2003) and 6,918,969 (2005) both to Zeeze et a.—but none similar to the Sealed Table Caster.
- During continuous steel casting the nature of the change from a liquid to solid phase is critical. At this moment physical and chemical conditions occur that will determine many mechanical properties and surface finish of the steel. These properties are related to the crystalline granular structure of the steel. The crystalline granule structure is determined by (1) keeping the difference in the temperature between liquid steel and the solidified steel to a minimum, (2) inducing flow or movement of the liquid steel across the solidifying dendrite, thus maintaining a consistent solution chemically and physically (3) insuring the high frequency of nuclei in the molten steel, and (4) allowing negative segregation to continue through the final solidification of the steel and eliminating inclusions. These factors are important in the formation of a high quality steel.
- At freezing point the liquid steel begins to solidify, crystalline structure form around the nuclei, the smallest aggregate of atoms on a crystalline lattice. Immediately dendrites crystalline lattice form having a periodicity that produces a long range order. Each dendrite grows until encountering other dendrites thus forming grain boundaries. The dendrite continues to grow in their precise cubic cell crystalline periodicity rejecting impurities in their growth. This rejection educes negative segregation accompanying the solidification of the steel
- During the solidification process segregation occurs. Negative segregation is the process of the impurities migrating transversely, perpendicular from the heat sink, and as the solidification in the liquid portion of the steel continues. Positive segregation is the accumulation of impurities in the confined liquid portion of the steel. Impurities collect in the liquid portion of the steel. This process is similar to the formation of sea ice and brine pockets. When sea ice dentrites form, the salt in the water is rejected in a process called brine rejection. As a result no salt is formed in the dentrites but is pushed into pockets or highly concentrated brine.
- In conventional continuous casting methods, as the steel solidifies the volume of liquid steel decreases and the impurities are concentrated in the void at the center of the casting. This creates defects in the center portion of the casting. For this reason vertical continuous casting methods result in a uniform quality along the steel but not transversely. There is also a tendency of porosity (pore grain bonding structure) and sometimes lamination at the center of the casting resulting from the rejection of impurities and positive segregation maturing to reverse negative segregation.
- As solidification takes place in the casting it is accompanied by segregation. The first parts of the casting that becomes solid are purer than the original liquid steel. This is the result of negative segregation (the impurities migrating away from the solid steel). Some elements and compounds are rejected from the crystalline structure as the solid is formed. The remaining liquid is richer in these rejected elements and compounds than was in the original liquid steel. This is called positive segregation. The preciseness of the crystalline structure may become overwhelmed in rejecting impurities and may now allow the impurities to be assimilated in the interstices of the grain boundaries as the impurities increase with positive segregation and solidification progresses. Negative segregation enhances the quality of the steel whereas positive segregation deteriorates the quality if the steel.
- In fixed mold casting the impurities in the liquid steel, may to a degree, migrates to the upper region of the ingot as solidification takes place at the bottom. The supper region of the ingot has accumulated a great portion of the impurities through segregation and circulation and buoyancy of the impurities. Consequently the lower section of the ingot usually has the higher quality of steel. Because the upper section has a high concentration of impurities the excess of the provision is usually cropped off and rejected during the slab rolling procedure.
- In the prevailing continuous casting, positive segregation at the center of the casting is a consequence of the negative segregation which precedes it from the heat sink of the casting and intensifies as the opposing solidifying locations meet. Positive segregation deteriorates the quality of the steel in the central portion of the casting. The trend has been to abrogate both negative and positive segregation by assimilating the impurities in the grain boundaries through increasing the grain boundaries area by creating a finer grain steel. This impedes migration of the impurities to the center of the casting, reducing positive segregation, this assimilation deteriorates what may have been the overall integrity of the steel.
- Accordingly, besides the other objects and advantages that will become apparent, the main objective of the present invention is to provide a continuous casting method and apparatus that promotes negative segregation without the consequence of positive segregation of the interior as the steel solidifies resulting in higher quality steel with minimal inclusions. Producing an equal axial fine grained crystalline structure being consistent chemically and physically, having excellent qualities such as: tensile strength, modulus of elasticity, toughness, ductility, workability, etc. Furthermore, the process described below has the object to reduce the cost for a superior nucleation agent, reduce the cost of decarbonization and deoxidization materials for producing a high quality steel void of oxidation point defects. The process also provides flexibility in casting dimensions, both width and thickness, thus reducing the operational and tool cost for producing a wider range of products and lowering the energy required for rolling reduction of the steel.
- Continuous casting with the Sealed Table Caster promotes negative segregation without advancing positive segregation in the center of the casting. Furthermore this enhances the bonding in the grain boundaries by minimizing impurities in the grain boundaries that weakens grain bonding. Moreover, the grain bonding is increased by the multiplicity of the degree of increasing the fine equal axial granules. Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
- It has been recognized that it would be advantageous to develop a continuous casting system that promotes negative segregation throughout the solidifying process resulting in a higher quality steel with a higher yield essentially eliminating inclusions in the steel. In addition, it would be advantageous to promote fine grain granules of equal axial dimensions to create greater bonding between granule structures.
- Briefly, and in general terms, the invention is directed to a sealed table caster. The sealed table caster has a chamber with an opening, to allow a liquid to flow into the chamber. A cooling belt running along the bottom of the chamber causes the liquid to solidify while maintaining a layer of liquid on top of the solidified portion of the liquid. The belt moves the solidified steel toward the exit of the chamber and the liquid is poured into the chamber such that is causes the liquid steel to circulate on the solidified steel. As the liquid solidifies the impurities migrate into the liquid leaving a solid with excellent properties. In addition, a cooled roller with the sealing roll both equipped with a scraper that may be places on top of the liquid to remove rejected impurities floating on the top layer of the liquid steel.
- Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:
-
FIG. 1 is a perspective view of a table caster in accordance with an embodiment of the present invention; -
FIG. 2 is a cross-sectional view of the table caster -
FIG. 3 is a perspective view and traverse section of the beginning section of the table caster -
FIG. 4 is a perspective view of cooling fountains -
FIG. 5 is a side view of a cooling fountain. -
FIG. 6 is a high temperature reactor. -
FIG. 7 is a phase diagram of the solubility of magnesium oxide with iron oxide. - Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.
- In accordance with
FIG. 1 thehorizontal table caster 10 has a receivingtube 12 connected to a tundish (not shown). Typical materials used in casting can be used in constructing the horizontal table caster and such materials are well known in the art. The top of thetable caster 10 hasremovable hood 14. Thehood 14 creates a sealedchamber 16 around coolingbelt 18.Chamber 16 can be any shape as long as it provides a seal aroundbelt 18. It is preferable forbelt 18 to be made of copper but any suitable material can be used.Gas inlet 20 allows a gas to enterchamber 16, creating a protective and cooling gaseous atmosphere andgas outlet 22 allows the gas to exit thechamber 16. The protective gas maintains an ideal gas coverage over the molten metal, gas free of harmful vapor. The gas can be a reducing or an inert gas such as carbon monoxide, carbon dioxide or argon.Hood 14 is cooled bywater duct 24.Duct 24 receives and discharges water from a pressurized water sources (not shown). The exit 26 (for the cast metal) ofchamber 16 is sealed by two inch sealing rolls 28. Therolls 28 keep gas from escapingchamber 16 while allowing the solidified steel to exit and assist in the constant movement of the solid steel.Chamber 16 is scaled on the opposite end by sealingrolls 29, -
Belt 18 is driven bydrive drum 30 and rotates aroundidler drum 32. Beltscrapers 34touches sealing rolls 29 andbelt 18.Drains 36 allow cooling water to exit the table and are provided with a gas seal (not shown). Pouring table 38 supports the cooling fountain which in turn supports the cooling belt and steel. Normalizing table 40 supports the steel during and after heat extraction has occurred and solidification and normalization is becoming completed. -
FIG. 2 shows a cross section of the sealed casting table 10.Circular deflector 42 is supported and rotated by an apparatus (not shown) and located down stream fromtube 12.Deflector 42 is made of a ceramic but it can be made of any suitable material. Optional cooling roller 44 rotates in a direction opposite the direction ofbelt 18. Roller 44 is cooled by a pressurized water source (not shown) and cleaned bydrum scraper 46. Coolingfountains 47 andbelt 18 are supported bystructural water boxes 48.Adjustable cooling walls 49 are located on either side and abovebelt 18.Walls 49 are adjusted withenvelope holding arms 49A.Water boxes 57 are connected to a pressurized water source (not shown). - Normalizing table 40 consist of
rollers 50 andbase rollers 52.Base rollers 52 are connected to bottom of table 40. Thetable caster 10 is supported byjack pedestal 55,jack 55A, and supports 55B and 55C. Table caster is adjusted withtension jack 55D. - Blow up 81 shows a magnified view of
table caster 10.Liquid steel 82 consists of two parts,upper portion 89 andlower portion 90. The liquid steel is located above the solidifiedsteel 92. Flow arrows 94 show how upper andlower portions steel 92. -
FIG. 3 illustrates a perspective cut section of one end of the horizontal table caster.Walls 49 are adjusted witharms 49A. The bottom of cooledside walls 49 hasgas sealing canal 56. Pressurized gas fillsgas sealing canal 56 to prevent leakage of molten metal under the cooledside wall 49 at a temperature well below boiling point. Thehood 14 is supported oncanal 58.Canal 58 is filled with runoff water to create a gas seal forchamber 16. Used cooling water flows intosluice trough 60 and outdrain 36. Cooling water also flows overhood 14 and is supplied byconduit 24. Cooling water flows overhood 14 throughconduit 24. -
FIG. 4 shows a perspective view of coolingfountains 47. Belt 18 (not shown) is supported by hydraulic pressure and floats on incoming water that flows thoughcontrol orifice 64 and overrim 62. Water flows to the underside of cooling belt 18 (not shown) throughflow control orifice 64.Bolts 66 provide support and anchor the coolingfountain 47 to water boxes 48 (not shown).Spacer 68 aligns adjacent cooling fountains together. -
FIG. 5 shows a side view of a coolingfountain 47.Alignment nipple 70 is used to set the cooling fountain in structural water boxes 48 (not shown). Sealingring 72 provides a water tight seal between the cooling fountain and the structural water boxes. -
FIG. 6 is thehigh temperature reactor 74 described in patent application Ser. No. 11/070527 filled Mar. 1, 2005, by Oren V. Peterson, entitled “Thermal Synthesis Production of Steel”FIG. 1 . Theliquid metal 76 flows outport 78 into a ladle (not shown).Tap hole 80 can be used to drain theslag bath 84 on top of the liquid metal bath. Operation . . .FIG. 2 ,FIG. 6 ,FIG. 7 , andFIG. 8 - The manner for using the
horizontal table caster 10 is a follows. Liquid steel is prepared by the process as described in patent application Ser. No. 11/070527 filled Mar. 1, 2005, by Oren V. Peterson, entitled “Thermal Synthesis Production of Steel” and as further processed as herein described. The phosphorus in the heat of the steel is oxidized to phosphorus pentoxide with the iron oxide in the metallic bath and rises up into the slag bath as the on going partial reduction process proceeds. Carbon is added on top of the slag bath near the final stage of iron partial reduction of the heat of steel to remove the phosphorus pentoxide, by reduction and evaporation, from the slag bath, theslag 84 is drained off throughtap hole 80 after the phosphorus removal is completed. Iron oxide and powdered magnesium oxide are then added to the bath. The iron oxide and magnesium oxide go into solution in the partially reduced metallic bath at temperatures above 2300 degrees Fahrenheit (SeeFIG. 7 ). Magnesium oxide has a simple cubicle crystalline structure. The magnesium oxide melting temperature is 5070 degrees Fahrenheit and iron oxide is 2300 degrees Fahrenheit, both are ionic bonds with the same valence so the iron oxide can substitute the magnesium oxide ion in the crystal structure allowing the magnesium oxide to go into solution both as liquid and suspended solid particles. The degree of solubility of magnesium oxide an iron oxide increase as temperature increases, thus the metallic bath temperature is now elevated. Once the degree of magnesium oxide is in solution with the iron oxide in the metallic bath, alloying materials and excess amounts of carbon are added into the solution and the carbon reacts with iron oxides in the solution. Excess amounts of carbon are added to reduce all metal oxides except the magnesium oxide, which is very chemically stable. Because the carbon deoxidation reaction is endothermic, carbon becomes an excellent deoxidation agent as metallic temperatures are increase. As a gas, the carbon oxides escape from the metallic bath leaving the iron, carbon and magnesium oxide and alloying materials in the solution. Because of the mass action of the excess carbon and carbon monoxide this process leaves the molten metallic bath near void of oxygen, other than the magnesium oxide nuclei which is chemically stable and serves as a solid nucleation agent. - The excess carbon can be removed by decarbonization. Decarbonization is the process of removing excess carbon by injecting carbon dioxide into the high temperature metallic bath. The carbon dioxide reacts with the carbon, at elevated temperatures, forming carbon monoxide and lowering the temperature of the metallic bath to casting temperature. This reaction removes the excess carbon from the metallic bath without oxidizing the iron. The magnesium oxide remains in the bath as nano-dimensional suspended solid particles that may serve as nuclei during solidification.
- The metallic bath flows out of the reactor and then is poured into a tundish. The liquid exits the tundish and enters
chamber 16 throughtube 12.Circular deflector 42 deflects the vertical flow of theliquid steel 82 into a fanned horizontal flow directed in the opposite direction of travel ofbelt 18. The addition of molten steel being poured onto the surface of the pool of liquid steel causes the upper strata of liquid steel to flow towards the sealingroll 29, which is water cooled from the interior of the roll. The movement of coolingbelt 18 and the flowing of the liquid steel intochamber 16 causes liquid portion of the steel to counter flow in strata on top of the solidified portion of the steel. The lower liquid portion of thesteel 90 moves faster, toward the sealing rolls 28 than the solid portion of thesteel 92. This movement causes developing dendrite to break off at a the ends, minimizing columnar structural granules in the steel and creating dendrite nuclei. The rate of flow of theliquid steel 82 intochamber 16, the temperature of coolingbelt 18, and the linear rate of the travel of the coolingbelt 18 is coordinated such that a constant level of liquid steel is maintained inchamber 16. The depth of liquid steel can be varied to produce different slab thicknesses. The induced flow mixes the liquid steel on the coolingbelt 18 with the pouredhot steel 82, normalizing its temperature and insuring a uniformed solution, temperature, and solidification rate throughout the entire length of the casting and solidifying surface. - As the solidification proceeds from the cooling
belt 18 to the surface of the liquid steel, fine granules of steel are forming, rejecting the impurities into the liquid steel. The fine granules form around the solid nano-dimensional magnesium oxide particles in the metallic bath solution. The liquid steel flows over the growing dendrite and breaks off the dendrite ends. This minimizes columnar growth, producing fragmented dendrite as nuclei, and carries the rejected impurities columnar growth, producing fragmented dendrite as nuclei, and carries the rejected impurities to the surface of the liquid steel. This rejection produces negative segregation resulting in minimal inclusions with a high purity of steel. - As the impurities are carried away by the flow of the steel, there is no subsequent positive segregation in the molten steel. Furthermore, as impurities are less dense than the liquid steel they float and remain at the surface of the liquid. The solidified steel travels longitudinal with the movement of the cooling
belt 18. The dendrite continues to multiply around the magnesium oxide and fracture dendrite nuclei and grow into granules as the solidification increases in thickness as it moves toward the normalizing table 40. The impurities are allowed to escape to the surface of the liquid steel minimizing their presence in the grain boundaries as solidification proceeds. As the impurities are eliminated from the grain boundaries, bonding in the fine granule structure is increased. Cooling roller 44 contacts the top surface of the liquid steel. As the top layer of liquid (having the highest concentration of impurities) touches roller 44 it solidifies and sticks to the roller.Scraper 46 then removes the solidified slag or impurities from the roller 44 and is dispensed. It is recognized that the roller 44 andscraper 46 are optional. The upper surface of the casting, containing the impurities, may be scarified or ground to remove impurities. - Cooling
belt 18 is supported by multiple coolingwater fountains 47. The cooling water fountains maintain the cooling belt in an effective cooling range of temperatures by flowing water (or any other suitable cooling agent) on the underside of the coolingbelt 18. The discharged water flowing from the coolingfountains 47 is collected insluice trough 60 and discharged through drains 36. In addition the liquid steel pool is contained by adjustable water cooledside walls 49. Adjusting the side walls allows different cast widths to be formed with the same casting table. The liquid steel is contained by seal rolls 29. Theroll cleaning scraper 34 is used to keep the belt onidler drum 32 and sealingroll 29 free of metal debris or scabs. - As the steel moves off the cooling
belt 18 it proceed or continues onrollers 50 towardpinch rollers 28. Back uprollers 52 supports the load of the steel as it moves acrossrollers 50. Expansion joint 54 are located above thedrive drum 30 to allow for differential movement in thetable caster 10. Expansion joint 54 allows for difference in linear expansion ofhood 14 andbase 38. Sealing pinch rolls 28 allow the solidified steel to exit, to assist in the constant movement of the casting, and to keep gas from escaping. - From the above description the advantages of the horizontal casting table become evident:
- (a) In the horizontal table caster solidification process from the bottom side of the steel surface, thus causing negative segregation to occur and proceeds traversal to the surface until the solidification process in complete, resulting in a superior casting of uniform steel with near complete segregation free of inclusions producing higher grades and yields.
- (b) The adjustable cooling walls allow for different widths of steel to be cast from the same caster.
- (c) The horizontal table caster allows for thinner and narrow castings of steel may maximizing the tonnage by producing longer castings.
- (d) The use of natural occurring magnesium oxide instead of metallic magnesium is better because it leaves the final product free of iron oxide which is required to produce magnesium oxide nuclei with metallic magnesium and it is also less expensive.
- (e) The use of magnesium oxide as a nucleation agent creates a finer grain steel with superior mechanical characteristics than steel using aluminum oxide as the nuclei. Natural occurring magnesium oxide produces much smaller nuclei than other nucleation agents such as aluminum oxide It is also less expensive than metallic magnesium and aluminum. The magnesium oxide is a smaller nucleus than the aluminum and the columbic forces the reduced repulsion in its molecule enhances more rapid dendrite forming characteristics, resulting in finer equal axial grain steel.
- (f) Excess carbon and carbon monoxide can be added to the metallic bath resulting in a complete reduction of iron oxide to metallic iron oxide metallic iron and carbon oxides enabling the formations of steel with fewer point defects.
- (g) Carbon dioxide can be injected into the molten steel to oxidize excessive carbon, leaving near zero oxygen residue in the metallic bath, also being capable of lowering carbon to very low quantity for micro alloying. Adding oxygen to the metallic bath to remove the carbon will oxidize portion of the iron and requires large quantities of expensive deoxidizers to only partially reduce the residue of oxygen in the steel.
- (h) The movement and flow of the liquid metal across and over the solidifying steel deters the growth of columnar grains and enhances the development of fine equal axial granule steel.
- While the foregoing examples are illustrative of the principles of the present invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts of the invention. Accordingly, it is not intended that the invention be limited, except as by the claims set forth blow.
Claims (20)
1. A table caster comprising:
(a) a chamber that is sealed so as to confine a gas in the chamber;
(b) a circular belt running horizontally along a bottom of the chamber;
(d) an opening in the chamber so as to allow a liquid to flow into the chamber and onto the belt;
(e) two rectangular walls located on both sides and adjacent to a top of the belt;
(f) two rotating cylinders located on an interior the belt;
(g) multiple cooling fountains located under a top portions of the belt;
(h) water flowing from the fountains uniformly suspending the belt;
(i) a void located inside each of the two rectangular walls; and
(j) an opening located at an end portion of the chamber.
2. the table caster in claim 1 , wherein said liquid is a metal
3. the table caster in claim 1 , wherein said belt is made of copper.
4. the table caster in claim 1 , wherein said walls are adjustable angular to the belt.
5. the table caster in claim 1 , wherein the suitable atmosphere is an inert gas.
6. the table caster in claim 5 , wherein said chamber has an inlet for the gas to enter the chamber and an outlet for the gas to exit the chamber.
7. A sealed table caster comprising:
(a) a sealed chamber that confine a gas in the chamber;
(b) an opening in a top portion of the chamber so as to allow a liquid to flow into the chamber;
(c) a circular defector located under the opening, the deflector positioned such that the liquid will deflect towards the front of the chamber,
(d) a belt along a bottom of the chamber positioned so that liquid entering the chamber will be placed on the belt.
(e) two rectangular walls located on both sides and adjacent to a top of the belt,
(f) a first means for rotating the belt so that the belt moves toward the back of the chamber,
(g) a second means for cooling the belt
(h) a third means for cooling the rectangular walls
(i) a forth means for allowing a solid to exit the chamber.
8. the table caster in claim 7 , wherein said liquid is a metal
9. the table caster in claim 7 , wherein said belt is made of copper.
10. the table caster in claim 7 , wherein said walls are adjustable in width perpendicular to the belt.
11. the table caster in claim 7 , wherein said chamber is filled with a reducing gas.
12. the table caster in claim 11 , wherein said chamber has an inlet for the gas to enter the chamber and an outlet for the gas to exit the chamber.
13. the table caster in claim 7 wherein a rotating cooled drum contacts the liquid and a means for scraping debris from the cooled drum.
14. the table caster in claim 7 wherein said walls have a bottom groove filled with a pressurized gas.
15. the table caster in claim 7 wherein the chamber has a rectangular removable hood.
16. the table caster in claim 15 wherein said removable hood has a cooling conduit along a top of the chamber.
17. the table caster in claim 15 wherein a side portion of the removable hood is sealed by a trough filled with water
18. A method for casting metal comprising the following steps:
(a) adding carbon to a slag bath to remove phosphorous pentoxide from the slag bath;
(b) removing the slag bath off a top layer of a partially reduced metallic bath;
(c) adding magnesium oxide and iron oxide to the partially reduced metallic bath;
(d) dissolving magnesium oxide in the partially reduced metallic bath causing the partially reduced metallic bath to contain an abundance of magnesium oxide;
(e) adding carbon to the partially reduced metallic bath;
(f) deoxidizing the partially reduced metallic bath with carbon into a metallic bath;
(g) injecting carbon dioxide into the metallic bath to de-carbonize the metallic bath; and
(h) lowering a temperature of the metallic bath to a casting temperature.
19. the method for casting metal in claim 18 where the partially reduced metallic bath is deoxidized with carbon monoxide.
20. the method for casting metal in claim 18 , further comprising the steps of:
(a) placing the metallic bath in a chamber with a cooling belt along a bottom of the chamber the cooling belt having a temperature that will cause the metallic bath to solidify;
(b) removing the heat of fusion from a bottom side of the metallic bath;
(c) solidifying a portion of the metallic bath commencing from one side producing a solidified metal on a top portion the belt with the metallic bath on a top portion of the solidified metal;
(d) moving a bottom portion of the metallic bath in a same direction as the solidified metal and at a faster rate than the solidified metal,
(e) moving a top portion of the metallic bath in the opposite direction of the solidified metal;
(f) allowing the metallic bath to completely solidify with impurities remaining on top of the solidified metal; and
(g) removing the solidified metal from the chamber.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/562,598 US7451804B2 (en) | 2006-11-22 | 2006-11-22 | Method and apparatus for horizontal continuous metal casting in a sealed table caster |
US12/242,880 US20090301686A1 (en) | 2006-11-22 | 2008-09-30 | Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/562,598 US7451804B2 (en) | 2006-11-22 | 2006-11-22 | Method and apparatus for horizontal continuous metal casting in a sealed table caster |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/242,880 Division US20090301686A1 (en) | 2006-11-22 | 2008-09-30 | Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster |
Publications (2)
Publication Number | Publication Date |
---|---|
US20080115906A1 true US20080115906A1 (en) | 2008-05-22 |
US7451804B2 US7451804B2 (en) | 2008-11-18 |
Family
ID=39415759
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/562,598 Expired - Fee Related US7451804B2 (en) | 2006-11-22 | 2006-11-22 | Method and apparatus for horizontal continuous metal casting in a sealed table caster |
US12/242,880 Abandoned US20090301686A1 (en) | 2006-11-22 | 2008-09-30 | Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/242,880 Abandoned US20090301686A1 (en) | 2006-11-22 | 2008-09-30 | Apparatus for Horizontal Continuous Metal Casting in a Sealed Table Caster |
Country Status (1)
Country | Link |
---|---|
US (2) | US7451804B2 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100243194A1 (en) * | 2009-03-27 | 2010-09-30 | Edward Luce | Stationary side dam for continuous casting apparatus |
US20100243196A1 (en) * | 2009-03-27 | 2010-09-30 | Daniel Godin | Continuous casting apparatus for casting strip of variable width |
CN106001515A (en) * | 2016-07-28 | 2016-10-12 | 嘉兴御创电力科技有限公司 | Molten steel precooling device and method |
US20170114427A1 (en) * | 2014-05-30 | 2017-04-27 | Baoshan Iron & Steel Co.,Ltd. | Method for directly producing pickling-free hot-plated sheet strip product from molten steel |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102017103046A1 (en) | 2017-02-15 | 2018-08-16 | Salzgitter Flachstahl Gmbh | Horizontal strip caster with optimized casting atmosphere |
CN109443885B (en) * | 2019-01-08 | 2021-02-02 | 中南大学 | A kind of rock triaxial tensile test specimen group device and its manufacturing method |
Citations (26)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3434691A (en) * | 1964-10-12 | 1969-03-25 | Clark H Hamilton | Valve |
US3512574A (en) * | 1966-12-02 | 1970-05-19 | Inland Steel Co | Continuous casting process and apparatus |
US3598175A (en) * | 1967-11-17 | 1971-08-10 | Olsson International | Apparatus for casting metal slabs and billets |
US3747966A (en) * | 1971-09-15 | 1973-07-24 | Deere & Co | Shaft coupling mechanism |
US3753459A (en) * | 1970-09-04 | 1973-08-21 | Concast Ag | Method and apparatus for cooling and guiding strands in continuous casting machines |
US3837392A (en) * | 1971-11-18 | 1974-09-24 | I Rossi | Apparatus for continuously casting steel slabs |
US3848656A (en) * | 1971-06-09 | 1974-11-19 | Battelle Memorial Institute | Process for cooling and supporting a continuously cast metal bar |
US3897906A (en) * | 1973-07-27 | 1975-08-05 | Voest Ag | Cooling device for strands that are to be cast continuously |
US3934641A (en) * | 1974-03-20 | 1976-01-27 | Fives-Cail Babcock | Cooling arrangement for continuously cast metal objects |
US3948311A (en) * | 1974-06-13 | 1976-04-06 | Massachusetts Institute Of Technology | Apparatus for casting metal slabs |
US4036281A (en) * | 1975-10-03 | 1977-07-19 | Irving Rossi | Method for continuously casting a slab |
US4036781A (en) * | 1974-10-16 | 1977-07-19 | Petro-Tex Chemical Corporation | Dehydrogenation catalyst |
US4047985A (en) * | 1976-02-09 | 1977-09-13 | Wean United, Inc. | Method and apparatus for symmetrically cooling heated workpieces |
US4443272A (en) * | 1981-09-19 | 1984-04-17 | Nippon Steel Corporation | Process for producing cold rolled steel sheets having excellent press formability and ageing property |
US4494594A (en) * | 1981-09-08 | 1985-01-22 | Amb Technology, Inc. | Spray cooling system for continuous steel casting machine |
US4716954A (en) * | 1986-10-24 | 1988-01-05 | Allegheny Ludlum Corporation | Method and apparatus for sequentially continuous casting different composition grades of steel |
US4751960A (en) * | 1986-03-18 | 1988-06-21 | Centre De Recherches Metallurgiques-Centrum Voor Research In De Metallurgie | Apparatus and method for cooling a continuously cast metal product |
US4765390A (en) * | 1986-05-13 | 1988-08-23 | Concast Service Union Ag | Method of and arrangement for cooling a continuously cast strand |
US4815519A (en) * | 1987-03-23 | 1989-03-28 | Dujardin Montbard Somenor Z. I. Lille-Seclin | Device for supporting and cooling a continuous casting emerging from a mold |
US5452756A (en) * | 1991-02-27 | 1995-09-26 | Yoshida Kogyo K.K. | Cooling method of continous casting |
US5716510A (en) * | 1995-10-04 | 1998-02-10 | Sms Schloemann-Siemag Inc. | Method of making a continuous casting mold |
US6250370B1 (en) * | 1998-05-28 | 2001-06-26 | Kawasaki Steel Corporation | Method for water-cooling hot metal slabs |
US6318449B1 (en) * | 1997-06-12 | 2001-11-20 | Sollac | Mould head for the vertical hot-top continuous casting of metal products elongate cross section |
US6328093B1 (en) * | 1998-05-30 | 2001-12-11 | Sms Schloemann-Siemag Aktiengesellschaft | Strand guiding segment for slab casting plants |
US6390177B1 (en) * | 1997-08-04 | 2002-05-21 | Giovanni Arvedi | Contact mould for the continuous casting of steel slabs |
US20030015260A1 (en) * | 1999-04-08 | 2003-01-23 | Nippon Steel Corporation | Cast steel and steel material with excellent workability, method for processing molten steel therefor and method for manufacturing the cast steel and steel material |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3423834A1 (en) * | 1984-06-28 | 1986-01-09 | Mannesmann AG, 4000 Düsseldorf | METHOD AND DEVICE FOR CONTINUOUSLY POURING METAL MELT, IN PARTICULAR STEEL MELT |
CA1299836C (en) * | 1986-09-29 | 1992-05-05 | William Lyon Sherwood | Continuous lead-float casting of steel |
US5392843A (en) * | 1993-03-25 | 1995-02-28 | Dolan; James J. | Continuous silver float casting of steel sheet or plate |
DE4407873C2 (en) * | 1994-03-04 | 1997-04-10 | Mannesmann Ag | Method and device for cooling molten steel |
-
2006
- 2006-11-22 US US11/562,598 patent/US7451804B2/en not_active Expired - Fee Related
-
2008
- 2008-09-30 US US12/242,880 patent/US20090301686A1/en not_active Abandoned
Patent Citations (29)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3434691A (en) * | 1964-10-12 | 1969-03-25 | Clark H Hamilton | Valve |
US3512574A (en) * | 1966-12-02 | 1970-05-19 | Inland Steel Co | Continuous casting process and apparatus |
US3598175A (en) * | 1967-11-17 | 1971-08-10 | Olsson International | Apparatus for casting metal slabs and billets |
US3753459A (en) * | 1970-09-04 | 1973-08-21 | Concast Ag | Method and apparatus for cooling and guiding strands in continuous casting machines |
US3848656A (en) * | 1971-06-09 | 1974-11-19 | Battelle Memorial Institute | Process for cooling and supporting a continuously cast metal bar |
US3747966A (en) * | 1971-09-15 | 1973-07-24 | Deere & Co | Shaft coupling mechanism |
US3837392A (en) * | 1971-11-18 | 1974-09-24 | I Rossi | Apparatus for continuously casting steel slabs |
US3897906A (en) * | 1973-07-27 | 1975-08-05 | Voest Ag | Cooling device for strands that are to be cast continuously |
US3934641A (en) * | 1974-03-20 | 1976-01-27 | Fives-Cail Babcock | Cooling arrangement for continuously cast metal objects |
US3948311A (en) * | 1974-06-13 | 1976-04-06 | Massachusetts Institute Of Technology | Apparatus for casting metal slabs |
US4036781A (en) * | 1974-10-16 | 1977-07-19 | Petro-Tex Chemical Corporation | Dehydrogenation catalyst |
US4036281A (en) * | 1975-10-03 | 1977-07-19 | Irving Rossi | Method for continuously casting a slab |
US4047985A (en) * | 1976-02-09 | 1977-09-13 | Wean United, Inc. | Method and apparatus for symmetrically cooling heated workpieces |
US4494594A (en) * | 1981-09-08 | 1985-01-22 | Amb Technology, Inc. | Spray cooling system for continuous steel casting machine |
US4443272A (en) * | 1981-09-19 | 1984-04-17 | Nippon Steel Corporation | Process for producing cold rolled steel sheets having excellent press formability and ageing property |
US4981531A (en) * | 1981-09-19 | 1991-01-01 | Nippon Steel Corporation | Process for producing cold rolled steel sheets having excellent press formability and ageing property |
US4751960A (en) * | 1986-03-18 | 1988-06-21 | Centre De Recherches Metallurgiques-Centrum Voor Research In De Metallurgie | Apparatus and method for cooling a continuously cast metal product |
US4765390A (en) * | 1986-05-13 | 1988-08-23 | Concast Service Union Ag | Method of and arrangement for cooling a continuously cast strand |
US4716954A (en) * | 1986-10-24 | 1988-01-05 | Allegheny Ludlum Corporation | Method and apparatus for sequentially continuous casting different composition grades of steel |
US4815519A (en) * | 1987-03-23 | 1989-03-28 | Dujardin Montbard Somenor Z. I. Lille-Seclin | Device for supporting and cooling a continuous casting emerging from a mold |
US5452756A (en) * | 1991-02-27 | 1995-09-26 | Yoshida Kogyo K.K. | Cooling method of continous casting |
US5716510A (en) * | 1995-10-04 | 1998-02-10 | Sms Schloemann-Siemag Inc. | Method of making a continuous casting mold |
US6318449B1 (en) * | 1997-06-12 | 2001-11-20 | Sollac | Mould head for the vertical hot-top continuous casting of metal products elongate cross section |
US6390177B1 (en) * | 1997-08-04 | 2002-05-21 | Giovanni Arvedi | Contact mould for the continuous casting of steel slabs |
US6250370B1 (en) * | 1998-05-28 | 2001-06-26 | Kawasaki Steel Corporation | Method for water-cooling hot metal slabs |
US6328093B1 (en) * | 1998-05-30 | 2001-12-11 | Sms Schloemann-Siemag Aktiengesellschaft | Strand guiding segment for slab casting plants |
US20030015260A1 (en) * | 1999-04-08 | 2003-01-23 | Nippon Steel Corporation | Cast steel and steel material with excellent workability, method for processing molten steel therefor and method for manufacturing the cast steel and steel material |
US6585799B1 (en) * | 1999-04-08 | 2003-07-01 | Nippon Steel Corporation | Cast steel piece and steel product excellent in forming characteristics and method for treatment of molted steel therefor and method for production thereof |
US6918969B2 (en) * | 1999-04-08 | 2005-07-19 | Nippon Steel Corporation | Cast steel and steel material with excellent workability, method for processing molten steel therefor and method for manufacturing the cast steel and steel material |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100243194A1 (en) * | 2009-03-27 | 2010-09-30 | Edward Luce | Stationary side dam for continuous casting apparatus |
US20100243196A1 (en) * | 2009-03-27 | 2010-09-30 | Daniel Godin | Continuous casting apparatus for casting strip of variable width |
US8122938B2 (en) | 2009-03-27 | 2012-02-28 | Novelis Inc. | Stationary side dam for continuous casting apparatus |
US8579012B2 (en) | 2009-03-27 | 2013-11-12 | Novelis Inc. | Continuous casting apparatus for casting strip of variable width |
US20170114427A1 (en) * | 2014-05-30 | 2017-04-27 | Baoshan Iron & Steel Co.,Ltd. | Method for directly producing pickling-free hot-plated sheet strip product from molten steel |
US10683561B2 (en) * | 2014-05-30 | 2020-06-16 | Baoshan Iron & Steel Co., Ltd. | Method for directly producing pickling-free hot-plated sheet strip product from molten steel |
CN106001515A (en) * | 2016-07-28 | 2016-10-12 | 嘉兴御创电力科技有限公司 | Molten steel precooling device and method |
Also Published As
Publication number | Publication date |
---|---|
US7451804B2 (en) | 2008-11-18 |
US20090301686A1 (en) | 2009-12-10 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US7451804B2 (en) | Method and apparatus for horizontal continuous metal casting in a sealed table caster | |
TWI326230B (en) | Casting steel strip with low surface roughness and low porosity | |
CN1170647A (en) | Casting steel strip | |
US6585799B1 (en) | Cast steel piece and steel product excellent in forming characteristics and method for treatment of molted steel therefor and method for production thereof | |
US3354937A (en) | Process and apparatus for continuous casting | |
JP5104153B2 (en) | Treatment method of joint slab in different steel type continuous casting | |
WO2000040354A1 (en) | Continuous casting billet and production method therefor | |
US3239899A (en) | Separating metals from alloys | |
US3414043A (en) | Method for the continuous transferring of liquid metals or alloys into solid state with desired cross section without using a mould | |
US3746070A (en) | Method for improving continuously cast strands | |
JPS58156519A (en) | Removal of slag from molten mixture of silicon and slag | |
JP2003251438A (en) | Continuous casting method of slab with few bubble defects and steel material processed from the slab | |
CA1179473A (en) | Continuous cast steel product having reduced microsegregation | |
US4269257A (en) | Method of sequential continuous-casting of different grades of steel | |
JP3817188B2 (en) | Thin slab manufacturing method using twin drum type continuous casting machine having scum weir and scum weir | |
US3940976A (en) | Method of determining the suitability of continuously cast slabs of Al- or Al-Si-killed soft steel for producing cold rolled sheets to be tinned | |
JPH07314097A (en) | Metal strip continuous casting method | |
JP4527832B2 (en) | Steel continuous casting method | |
JP7389335B2 (en) | Method for producing thin slabs | |
JPH11192539A (en) | Continuous casting method of chromium-containing molten steel with excellent internal defect resistance | |
JPH10249498A (en) | Method for continuously casting high cleanliness steel with tundish providing field weir closing bottom part | |
JP2888155B2 (en) | Continuous casting method of ultra low carbon steel containing Ti | |
SU1404159A1 (en) | Method of producing ingots from rimmed steel | |
JPS591141B2 (en) | Metal casting method and its equipment | |
JP3356094B2 (en) | Manufacturing method of round billet slab by continuous casting |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
FPAY | Fee payment |
Year of fee payment: 4 |
|
REMI | Maintenance fee reminder mailed | ||
LAPS | Lapse for failure to pay maintenance fees | ||
STCH | Information on status: patent discontinuation |
Free format text: PATENT EXPIRED DUE TO NONPAYMENT OF MAINTENANCE FEES UNDER 37 CFR 1.362 |
|
FP | Lapsed due to failure to pay maintenance fee |
Effective date: 20161118 |